Engine Mechanical:
Detailed disassembly, assembly, inspection, and repair procedures for all engine components (pistons, rings, bearings, valves, camshafts, crankshaft, etc.). Includes timing belt/chain replacement, cylinder head service, and block machining specifications.
Engine Fuel System:
Bosch L-Jetronic fuel injection system diagnosis and repair, fuel pump, injectors, fuel pressure regulator, fuel filter replacement, and troubleshooting.
Engine Ignition System:
Ignition timing, spark plugs, ignition coils, distributor, ignition control module (if applicable), and troubleshooting.
Cooling System:
Radiator, water pump, thermostat, hoses, fan operation, and coolant specifications and flushing procedures.
Exhaust System:
Exhaust manifold, catalytic converter (if equipped), muffler, and pipe replacement and inspection.
Transmission Manual:
Service, repair, and overhaul procedures for Getrag 260 5-speed manual transmission. Clutch replacement, flywheel service, and gearbox fluid specifications.
Transmission Automatic:
Service, repair, and diagnosis for ZF 4HP22 automatic transmission (if applicable to specific models/trims). Transmission fluid and filter replacement, shift linkage adjustment.
Drivetrain:
Driveshaft, CV joints, differential (rear axle), axle shafts, and wheel bearing service.
Suspension Front:
McPherson strut, control arms, ball joints, sway bar, bushings, and alignment specifications.
Suspension Rear:
Trailing arms, shock absorbers, springs, bushings, and alignment specifications.
Steering System:
Power steering pump, steering rack, tie rods, steering column, and fluid specifications.
Brake System Front:
Front disc brakes, calipers, rotors, brake pads, and hydraulic lines. ABS system diagnosis (if equipped).
Brake System Rear:
Rear disc brakes, calipers, rotors, brake pads, and hydraulic lines. Parking brake mechanism.
Electrical System Charging:
Alternator, voltage regulator, battery, and wiring.
Electrical System Starting:
Starter motor, starter solenoid, and ignition switch.
Electrical System Lighting:
Headlights, taillights, interior lighting, fuses, relays, and wiring diagrams.
Electrical System Accessories:
Power windows, door locks, mirrors, horn, wipers, washers, and climate control systems.
Body Exterior:
Body panel removal and installation, doors, hood, trunk, bumpers, glass, seals, and alignment.
Body Interior:
Dashboard removal, instrument cluster, seats, upholstery, carpeting, and trim panels.
HVAC System:
Heater core, blower motor, A/C compressor, refrigerant lines, climate control panels, and servicing.
Routine Maintenance:
Oil and filter changes, air filter replacement, spark plug replacement, coolant flushes, fuel filter replacement, belt inspections and replacements.
Troubleshooting:
Diagnostic flowcharts and symptom-based troubleshooting for engine, electrical, and mechanical issues.
Repair And Rebuild:
Step-by-step instructions for component removal, disassembly, repair, reassembly, and installation.
Component Replacement:
Detailed guides for replacing common wear items and major components.
Alignment And Adjustment:
Wheel alignment specifications and adjustment procedures, clutch pedal adjustment, and idle speed adjustments.
Wiring Diagrams:
Comprehensive electrical wiring diagrams for all systems.
Depth:
Comprehensive, covering everything from basic scheduled maintenance to full engine and transmission rebuilds. Suitable for professional mechanics and experienced DIY enthusiasts.
Oil Change Interval:
Typically every 5,000-7,500 miles or 6-12 months, depending on driving conditions and oil used. Check manual for specific recommendation.
Timing Belt Interval:
M20 engines use a timing belt. Replacement is critical, usually around 50,000-60,000 miles or 4-5 years due to degradation. Consult manual for exact interval and procedure.
Spark Plug Replacement:
Typically every 20,000-30,000 miles, or as specified by plug type.
Engine Oil Type:
API SG or higher, SAE 10W-40 or 20W-50 recommended (verify with manual for ambient temperature ranges).
Engine Oil Capacity:
Approx. 4.75 liters (5.0 US quarts) with filter change for M20B27.
Coolant Type:
Ethylene glycol-based coolant (e.g., BMW Blue or equivalent). Mixture 50/50 with distilled water.
Transmission Fluid Manual:
API GL-4 or GL-5 gear oil, SAE 75W-90 or 80W-90 (verify with manual).
Transmission Fluid Automatic:
Dexron-III (or equivalent), consult manual for exact specification.
Power Steering Fluid:
ATF Dexron-II or Dexron-III (verify with manual).
Brake Fluid:
DOT 3 or DOT 4 brake fluid (verify with manual).
Engine Mounts:
Worn engine mounts are common, leading to vibration and clunking under acceleration/deceleration.
Fuel Injector Seals:
Leaking fuel injector seals can cause rough idling, fuel smell, and starting issues.
Heater Control Valve:
Common failure point leading to no heat or overheating issues.
Window Regulators:
Manual and electric window regulators can fail over time, causing windows to not operate correctly.
Rubber Bushings:
Age-related degradation of rubber bushings in suspension, subframes, and steering can affect handling and ride quality.
Coolant Leaks:
Plastic thermostat housing and expansion tank can become brittle and crack, leading to coolant leaks.